The high flexibility of profile bending with hyperelastic pad enables it to be a promising method for small lot or single part production, especially for space frame and roof-rail parts in automotive and aerospace industries. Bending of two aluminum profiles with different sections was carried out to investigate the effect of main process parameters on the bending process. Results show that the shape of the cross-section and its relative thickness and section modulus in bending are the main factors that determine the bending properties of the profiles. Roller stroke, properties of polyurethane pad and constraints on profiles are key factors that determine the bending radius and section deformation of bent profiles. Failures and quality problems met in experiments were also analyzed.